Core yarn comprising core thread with variant drawing, and fabric that is obtained from this core yarn

ABSTRACT

A core yarn including at least one core part. The at least one core part includes at least one elastane thread having a plurality of areas with different densities and/or, the at least one core part includes at least one filament thread having a plurality of areas with different densities and are made of regenerated or synthetic materials.

CROSS REFERENCE TO THE RELATED APPLICATIONS

This application is the national phase entry of International Application No. PCT/TR2017/050719, filed on Dec. 28, 2017, which is based upon and claims priority to Turkish Patent Application No. 2017/01808, filed on Feb. 7, 2017, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The invention is related to core yarns and fabrics that are obtained from these threads, in textile sector. The invention is specifically related to a core yarn comprising thread with variant drawing in the core part, method for obtaining said core yarn and the fabric that is made from this thread.

BACKGROUND

Currently, threads of various qualities are used in textile fabric and knitted fabrics in order to obtain different looks and different properties. By altering the thread properties, different visual effects are obtained in the textile fabric or in the knitting structure and fabric properties are improved.

In the standard thread production, process steps such as, threshing, carding, cresting, traction, roving and spinning are applied. Thread cords that are formed, become usable thread after they are attenuated and winded in the ring thread machines. By this thread production method, textile and knitting threads are obtained.

In the prior art, corn yarns comprising thread in the core, or threads not comprising a separate thread, are produced. Core thread is obtained by feeding at least one filament thread which is made from regenerated, or synthetic materials and an at least one elastane thread or only at least one elastane thread to the thread core during the spinning step of the natural fibers (cotton etc.), regenerated fibers, synthetic fibers or a combination of these.

The threads that manifest the property of elongation to an extent when pulled by any force, and return to their original state when the pulling force disappears, are made of polyurethane-elastomer and are called elastane. Elastane thread cannot be used per se. It is used as auxiliary thread along with the main thread in the fabric.

At the present time, elastane thread is commonly used in the circular knitting machines. Elastane thread usage is more common especially in fine circular knitting machines. These are single jersey, rib knit, interlock, ringel, electronic jacquard, mini jacquard circular knitting machines. Elastane thread is solely used on its own along with the ground threads in circular knitting machines as well as it is used as lined thread.

In the prior art, only feeding of elastane and/or filament thread is performed by fixed drawing in the standard core yarn production and a variation cannot be provided during the elastane/filament thread feeding. Elastane and filament thread are fed to the thread core by the rotation of the rollers which drive the reels where the threads are winded. Since the rotation velocity of said rollers is fixed, the elastane and filament thread flow also occur in fixed (with a predetermined fixed drawing) velocity. In the Core yarn production, the elastane and filament thread feed can be continued with the same velocity during the thread production as the velocity that is used for the elastane and filament thread feed in the beginning of the production. By this way, the elastane and filament thread is fed to the thread hub with a fixed tensility during the thread production.

Improvements regarding the issue that are known in the prior art are provided below.

Patent with publication number EP2452002B1 is related to “A core yarn production device and its method”. The device of the invention comprises a first and a second couple of unwinding rollers; wherein these rollers are located one after another with a certain distance between them in a horizontal direction and they are driven. A first and a second deflection roller are arranged in the head of the core filament bobbin in a manner to deflect a core filament twice by unwinding the core filament from the core filament bobbin before it enters the spinning process of the mil and consequently to reduce the swing within the core filament.

Patent with publication number EP2329067B1 is related to “A supervision method in the corn yarn production and its setting for use”. The supervision setting of the invention comprises a separation setting which is located in the entrance of the tentering mechanism and which is used for interrupting the feeding of the fibers to the tentering mechanism according to the tentering level of the filament and which comprises a back deflection reel for deflection (reversing) of the filament; and a front deflection reel which is located on a tentering (drawing) mechanism with an angle that is inclined with respect to the dispatch roller and which is used for deflection a filament.

As a result, due to the inadequacies that are mentioned above and the insufficiency of the current solutions regarding the issue, an improvement is considered necessary in the technical field.

SUMMARY

The present invention is related to a core yarn comprising core thread with variant drawing which fulfills the requirements that are mentioned above, and eliminates all disadvantages and provides some advantages, and fabric that is made of this core yarn.

The primary goal of the invention is to enable forming an effect with different visuality in textile and knitted fabrics.

The invention aims to develop textile and knitted fabrics that are obtained from core yarns comprising elastane and/or filament thread, where a non-fixed drawing is applied in their cores.

An aim of the invention is to provide the feeding of elastane and/or filament threads to the thread core with a variant velocity during the production of the core yarn.

In addition to these, the invention also aims that elastane and/or filament threads that are fed to the core of the thread in core yarns have a variant drawing value.

Another aim of the invention is to enable obtaining different visual effects (pattern design) in the textile and knitted fabrics via the core yarns.

In order for the aims mentioned above to be achieved, the invention is a core yarn obtained from natural fibers, regenerated fibers, synthetic fibers or fibers that are a combination of these; wherein it comprises in its core part,

-   -   at least one elastane thread comprising areas to which different         drawing values are applied, and/or,     -   at least one filament thread comprising areas to which different         drawing values are applied, and are made of regenerated or         synthetic materials.

In order for the aims of the present invention to be achieved, it is possible that said areas have different lengths and density along the elastane thread and/or filament thread or that said areas have same lengths and densities along the elastane thread and/or filament thread.

In order for the aims of the present invention to be achieved, the production method of core yarn comprises the process steps of;

-   -   preparing the natural fibers, regenerated fibers, synthetic         fibers or the fibers that is a combination of these fibers, for         the spinning process and roving into cord,     -   applying the spinning process to the obtained cord,     -   feeding at least one filament thread and that is comprised of         the regenerated or synthetic materials or at least one elastane         thread with different drawing values to the core part of the         cord which is drawn during the spinning process,     -   applying twisting and winding to bobbin.

In order for the aims of the present invention to be achieved, it is a thread spinning setting which enables the application of said core yarn production method after the step of roving; wherein it comprises;

-   -   feeding part,     -   drawing part comprising back, middle and front drawing rollers         that are located one after another, a back sleeve which is         located on said back drawing roller, a middle sleeve which is         located on said middle drawing roller and a front sleeve which         is located on said front drawing roller,     -   twisting and winding parts

wherein the thread spinning setting comprises;

-   -   elastane thread drive roller in which the elastane thread reel         is attached and which provides the feeding of the elastane         thread to the drawing part; drive motor and inverter which         provides the movement to the elastane thread drive roller and         which can alter the velocity of the elastane thread drive         roller; and a data entrance screen on which the velocity values         depending on the length of the elastane thread are entered;         and/or     -   filament thread drive roller which provides the feeding of the         filament thread to the drawing part; drive motor and inverter         which provides the movement to the filament thread drive roller         and which can alter the velocity of the filament thread drive         roller; and a data entrance screen on which the velocity values         depending on the length of the filament thread are entered.

In order for the aims of the present invention to be achieved, said spinning setting comprises a elastane thread drive roller which provides the feeding of the elastane thread in between the front drawing roller and the front sleeve during the drawing, and a filament thread drive roller which provides the feeding of the filament thread in between the front drawing roller and the front sleeve during the drawing.

The structural and characteristical features of the invention along with all its advantages shall be understood more clearly with the figures provided below and the detailed description that refers to these figures. Therefore, an evaluation shall be made by taking these figures and the detailed description into account.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE shows a representative schematic view of the spinning setting which enables obtaining the core yarn of the invention comprising core thread with variant drawing.

The drawings do not need to be necessarily scaled and the details that are not required for understanding the present invention may be overlooked. In addition to that, the elements that are identical at least in a large extent or which have functions that are identical at least in a large extent are represented with the same number.

DESCRIPTION OF THE PART REFERENCES

-   10. Cord -   11. Cord bobbin -   20. Filament thread -   21. Filament thread bobbin -   22. Filament thread drive roller -   30. Elastane thread -   31. Elastane thread reel -   32. Elastane thread drive roller -   40. Data entrance screen -   50. Drive motor -   60. Inverter -   70. Front drawing roller -   71. Front sleeve -   80. Middle drawing roller -   81. Middle sleeve -   90. Back drawing roller -   91. Back sleeve -   100. Cop -   101. Eyelet -   102. Separator -   103. Antibalon collet -   104. Block

DETAILED DESCRIPTION OF THE EMBODIMENTS

In this detailed description core yarn of the invention comprising core thread with variant drawing and fabric which is obtained from this core yarn and its preferred structurings are described in a non-limiting manner in order for the issue to be understood more clearly.

The invention is a core yarn that is obtained from natural fibers (cotton etc.), regenerated fibers, synthetic fibers or a combination of these and it comprises in its core part;

-   -   at least one elastane thread (30) comprising areas to which         different drawing values are applied, and/or,     -   at least one filament thread (20) comprising areas to which         different drawing values are applied, and are made of         regenerated or synthetic materials.

It is possible that said areas to which different drawing values are applied, have different lengths and densities along the elastane thread (30) as well as it is possible for these to have same lengths and densities. It is possible that said areas have different lengths and densities along the filament thread (20) or they have the same lengths and densities. In cases which the elastane thread (30) and the filament thread (20) are used together, it is possible that said threads (20, 30) have areas to which same or different drawing values are applied and which have same or different lengths.

The core thread of the invention is obtained by feeding; at least one filament thread (20) that is obtained from regenerated or synthetic materials and/or at least one elastane thread (30) to the thread core during the spinning process of the cords (10) which are obtained from natural fibers (cotton etc.), regenerated fibers, synthetic or a combination of these fibers. By applying process steps of threshing, carding, cresting, traction, roving vb. respectively to the Natural fibers, regenerated fibers, synthetic fibers or a combination of these, said fibers are being prepared for the spinning process.

Within the scope of the invention, mostly pes and pbt filaments are primarily preferred; however, a filament thread (20) made from different material can also be used. The type of the filament thread (20) is related to the usage area of the final fabric. Here, material refers to the raw material which the filament threads (20) are made from. These raw materials are materials that are obtained by the regeneration of the cellulose-based vegetable materials or chemical-based materials (petroleum etc.) that are obtained by artificial methods.

Production method of the core yarn of the invention generally comprises process steps of;

-   -   preparing the natural fibers, regenerated fibers, synthetic         fibers or the fibers that is a combination of these fibers, for         the spinning process and roving into cord (10),     -   applying the spinning process to the obtained cord (10),     -   feeding at least one filament thread (20) that is comprised of         the regenerated or synthetic materials and/or at least one         elastane thread (30) with different drawing values to the core         part of the cord (10) which is drawn during the spinning         process,     -   applying twisting and winding to bobbin.

Core yarn of the invention is obtained by applying process steps of threshing, carding, cresting, traction, roving and spinning respectively to the fibers consisting of natural fibers, regenerated fibers, synthetic fibers or a combination of these, and afterwards feeding the filament thread or threads (20) which is/are obtained from regenerated or synthetic materials with elastane thread or threads (30), to the thread core during the spinning process. By applying process steps of threshing, carding, cresting, traction, roving vb. respectively to the Natural fibers, regenerated fibers, synthetic fibers or a combination of these, said fibers are being prepared for the spinning process.

Regarding the fabric of the invention, firstly the grammage, elasticity and recovery properties that the fabric shall have, are determined according to the place of use. Afterwards, depending on the grammage, the thread number that will be used for obtaining the fabric is determined. For instance, for a fabric weighing 320 gr/m² the core thread with 20/1 as final thread number is chosen. After that, depending on the aggregation value, which is chosen according to the place of use, the type of the filament thread (20) (pes, nylon, pbt, floss viscose etc.), the thickness of the filament thread (20) to be used and the number of pieces in the core (1, 2 or more pieces of filament thread (20) is used depending on the desired aggregation value) are determined. In the same manner, depending on the elasticity value, which is chosen according to the place of use, the type of the elastane (30), the thickness of the elastane and the number of pieces in the core (1, 2 or more pieces of elastane thread (30) is used depending on the desired aggregation value) are determined. The production of the core thread, which shall be used in the fabric production, is performed after the grammage, elasticity and recovery properties of the fabric; the number of the thread to be used in the fabric production, the types of the filament thread (20) and the elastane thread (30) that shall be used in said thread core, their thicknesses and pieces of use are determined. The formed threads are turned into fabric with fabric width, fabric grammage and machine settings that are appropriate for the desired circular knitting construction (interlock, rib knit, single jersey etc.) which is suitable for garment industry or in flat knitting garment industry or as textile type and afterwards dyeing process, is performed.

The spinning setting of the core yarn of the invention, which enables obtaining the natural fibers, regenerated fibers, synthetic fibers or the fibers that is a combination of these after the step of it being prepared for the spinning step and being turned it into cord (10), is generally comprised of,

-   -   feeding part,     -   drawing part,     -   twisting and winding parts.

In the feeding part;

-   -   warping creel onto which the cord and filament thread bobbins         (11,21) is attached,     -   drive roller (22) which enables the unwinding and flow of the         filament thread (20)     -   drive motor (50) and inverter (60) which drive the filament         thread drive roller (22) and can alter the velocity of the drive         roller (22),     -   data entrance screen (40) onto which the velocity values         depending on the length is entered for the filament thread (20),     -   filament thread (20) guides,     -   filament thread (20) guiding pipe,     -   drive roller (32) onto which elastane thread reel (31) is         attached and which enables the unwinding and flow of the         elastane thread (30),     -   drive motor (50) and inverter (60) which drive the elastane         thread drive roller (32) and can alter the velocity of the drive         roller (32)     -   data entrance screen (40) onto which the velocity values         depending on the length is entered for the elastane thread (30),     -   elastane thread (30) guides,     -   separator which separates the elastane thread reels (32) from         one another,     -   elastane thread (30) and filament thread (20) sensors,     -   fibers cord stopper which stops the flow of the cord (10) in         case that the elastane thread (30) and filament threads (20)         break,     -   display screen are comprised.

In the Drawing part;

-   -   back, middle and front drawing rollers (70,80,90) that are         located one after another,     -   back sleeve (91) (printing roller) which is located on said back         drawing roller (90),     -   middle sleeve (81) (printing roller) which is located on said         middle drawing roller (80),     -   front sleeve (71) (printing roller) which is located on said         front drawing roller (70),

which enable the attenuation and straightening of the cord (10) during the spinning step, are located.

In the twisting and winding parts;

-   -   eyelet (pig-tailed) (101),     -   separator (102),     -   antibalon collet (103),     -   cop (100),     -   block (104) are comprised.

The cord (10) comprising the main material of the core yarn of the invention, is winded around the cord bobbin (11). filament thread (20), which is the material enabling elasticity, endurance, aggregation capacity by being fed into the main material during the spinning step, is winded on the filament thread bobbin (21). On the other hand elastane thread (30), which is the material enabling elasticity by being fed into the main material during the spinning step, during the spinning step, is winded on the elastane thread reel (31). Cord bobbins (11) and filament thread bobbins (21) are attached to the respective parts in the bank creel section in the feeding part and the elastane thread reel (31) is attached to the drive roller (32). The cord (10) that is fed to the drawing part from the Cord bobbin (11) passes through the back (90), middle (80) and front drawing rollers (70) that are located one after the other in this section, and the back (91), middle (81) and front sleeves (71), and is exposed to drawing and attenuates. Meanwhile, the elastane thread (30) and/or the filament thread (20) is also fed in between the front drawing roller (70) and the front sleeve (71) and is taken off via the cord (10). During said drawing process, the elastane thread (30) and/or the filament thread (20) is not fed with a fixed velocity. Consequently, different drawing values are applied to the elastane thread (30) and/or the filament thread (20). Depending on the desired length, the feeding velocity values vary for the elastane thread (30) and/or the filament thread (20). In order to provide the variance in velocity depending on the length; elastane thread (30) data entrance screen (40), elastane thread (30) drive motor (50) and elastane thread (30) inverter (60) are added to the spinning setting for the elastane thread (30). In a similar manner, in order to provide the variance in velocity depending on the length; filament thread (20) data entrance screen (40), filament thread (20) drive motor (50) and filament thread (20) inverter (60) are added to the spinning setting for the filament thread (20). The data entrance screen (40) is the screen on which the designed thread length and the velocity value depending on this length are entered. The values that are obtained from here are transmitted to the drive motor (50) via the inverter (60) and the movement of the drive rollers (22, 32) is altered in the desired manner. The inverter (60) transmits the command, which it obtains from the data entrance screen (40) in order to alter the feeding velocity of the elastane thread (30) and filament thread (20), to the drive motor (50). The drive motor (50) alters the velocity of the elastane thread and filament thread drive rollers (32, 22) according to the command it receives from the inverter (60). Therefore, the elastane thread (30) and/or filament thread (20) with variant drawing values are fed to the hub of the spinned cord (10). Preferably, servo motor is used as the drive motor (50).

The elastane thread (30) and/or filament thread (20) is fed to the core of the cord (10) and final core yarn is obtained by applying twisting and winding processes to the cord (10). The obtained thread is winded to the cops (100). The cops (100), is the bobbin to which the spinned thread is winded. While the spinned thread is being winded to said cops (100), it goes through the eyelet (101) which guides said thread.

In the prior art, in core yarn production, the flow of elastane and filament thread (30, 20) is provided in a fixed velocity (a predetermined fixed drawing). The reason behind this is that the fabric is desired to have the same elasticity at all points. In the prior art, it is not possible for the drive rollers (32, 22), which provide the elastane and filament thread (30, 20) flow, to speed up or slow down. In order to provide a variation of velocity in this movement a servo motor (50), which is connected to the data entrance screen (40) with the help of an inverter (60), is placed onto thread spinning setting. The added servo motor (50) provides an increase or a decrease in the instantaneous amount of feeding by making the elastane and filament thread drive rollers (22,32) roll with different velocities by the command it receives from the data entrance screen (40). Since the velocity of the front drawing roller (70) and the front sleeve (71) to which the Elastane thread (30) and the filament thread (20) are fed to the different of the variant velocities provide different drawing values for the feeding of the elastane and filament thread (30,20).

Areas to which different drawing values are applied, are obtained by feeding with different tensilities. Depending on the tensility extent, it is possible that said areas have same or different lengths and densities.

By the virtue of the invention, it is aimed to produce a core yarn comprising areas with different elasticities and knitting and textile fabrics that are made from this yarn. Therefore; it is possible to create effects that are not done before.

By the virtue of the invention elastane and filament thread (30, 20), that are fed in the core thread (core yarn) production, are provided to the thread hub with different drawing variations. In the present core thread systems, the elastane and filament thread (20, 30) are fed to the system with one single value of drawing, which is given when the production starts. By the virtue of the invention these drawing values can be arranged in the desired length ranges.

In the present applications, the elastane thread drive roller (32) and the filament thread drive roller (22) roll with a fixed velocity. By the virtue of the invention, the elastane thread drive roller (32) and the filament thread drive roller (22) may roll with different velocities due to the data entrance screen (40), inverter (60) and servo motor (50) which are integrated to the thread spinning setting.

Therefore the elastane and/or filament thread (30, 20) with different tensilities are unreeled and fed, consequently the production of core thread with different drawing values may be achieved. Data are entered to data entrance screen (40) for rolling with different velocities and rolling locations and these data are transmitted to the servo motor (50) via inverter (60) and the velocity of the drive rollers (22,32) may be altered. By this manner, it is provided that the elastane and/or filament thread (20, 30) are fed with different densities. As a result, a core yarn, comprising elastane and/or filament thread (20,30) with different take off values, is produced and 3-dimensional fabric production is achieved by knitting or weaving these threads. 

What is claimed is:
 1. A core yarn comprising at least one core part, wherein, the at least one core part comprises at least one elastane thread having a plurality of areas with different densities and/or, the at least one core part comprises at least one filament thread having a plurality of areas with different densities and are made of regenerated or synthetic materials.
 2. The thread according to claim 1, wherein; the plurality of areas of the at least one elastane thread have different lengths and densities along the at least one elastane thread.
 3. The thread according to claim 1, wherein; the plurality of areas of the at least one elastane thread have same lengths and densities along the at least one elastane thread.
 4. The thread according to claim 1, wherein; the plurality of areas of the at least one filament thread have different lengths and densities along the at least one filament thread.
 5. The thread according to claim 1, wherein; the plurality of areas of the at least one filament thread have same lengths and densities along the at least one filament thread.
 6. A method of production of the core yarn of claim 1, the method comprising the steps of: preparing natural fibers, regenerated fibers, synthetic fibers or fibers having a combination of the natural fibers, regenerated fibers and the synthetic fibers for a spinning process and roving into a cord; applying the spinning process to the cord; feeding the at least one filament thread comprising of regenerated or synthetic materials and/or the at least one elastane thread, with different drawing values to a core part of the cord drawn during the spinning process; applying twisting and winding to a bobbin.
 7. A thread spinning setting of the method according to claim 6, which enables an application of the method of production of the core yarn after the step of roving the cord; wherein the thread spinning setting comprises: a feeding part, a drawing part comprising a back drawing roller, a middle drawing roller and a front drawing roller located one after another, a back sleeve located on the back drawing roller, a middle sleeve located on the middle drawing roller and a front sleeve located on the front drawing roller; twisting and winding parts; an elastane thread drive roller having a elastane thread reel attached therein for feeding of the at least one elastane thread to the drawing part and/or a filament thread drive roller for feeding the at least one filament thread to the drawing part; a drive motor and an inverter for providing a movement to the elastane thread drive roller and alter a velocity of the elastane thread drive roller and/or for providing a movement to the filament thread drive roller and alter a velocity of the filament thread drive roller; and a data entrance screen, wherein velocity values depending on a length of the at least one elastane thread and/or the at least one filament thread are entered in the data entrance screen.
 8. The thread spinning setting according to claim 7, wherein the elastane thread drive roller feeds the at least one elastane thread in between the front drawing roller and the front sleeve in the drawing part, and/or the filament thread drive roller feeds the at least one filament thread in between the front drawing roller and the front sleeve in the drawing part.
 9. A fabric comprising the core yarn according to claim
 1. 10. The fabric according to claim 9, wherein the fabric is a textile or a knitted fabric.
 11. The fabric according to claim 9, wherein, the plurality of areas of the at least one elastane thread have different lengths and densities along the at least one elastane thread.
 12. The fabric according to claim 9, wherein, the plurality of areas of the at least one elastane thread have same lengths and densities along the at least one elastane thread.
 13. The fabric according to claim 9, wherein, the plurality of areas of the at least one filament thread have different lengths and densities along the at least one filament thread.
 14. The fabric according to claim 9, wherein, the plurality of areas of the at least one filament thread have same lengths and densities along the at least one filament thread. 